The present invention refers to an arc welding torch in particular of the type MIG or MAG respectively acronyms of the english terms "Metal-arc Inert Gas" and "Metal-arc Active Gas", or also known with the term GMAW acronym of the english term "Gas Metal Arc Welding", which means arc welding with metal under gas protection.
The arc welding torch of type MIG or MAG has three functions:
With reference to
Inside said lance body 81 a wire guide 88 is further inserted inside which said welding wire advances.
With reference to
Said welding torch 80 further comprises a metallic contact tip 82 which is inserted into said contact metallic tip holder 87 and from which it receives said electric current.
Said contact tip 82 is also capable of transferring said electric current to the welding wire, so that between the welding wire and a piece to be welded an electric arc is formed capable to melt the welding wire by determining a welding bath.
The contact tip 82 is in fact provided with a through bore 83 inside which the welding wire passes, and is capable of transferring said electric current to the welding wire by contact with the same inside said through bore 83, and consequently based upon the diameter of the welding wire it is necessary to have a contact tip with a diameter corresponding approximately to the welding wire.
Said metallic tip holder 87 also permits to change said contact tip 82 in case of changing the welding wire with another one having a different diameter or in case of an excessive wear of the contact tip 82 itself.
Typically said diffuser element 84 is realized in a ceramic material or in a reinforced polyester and is able to diffuse said protection gas through a series of radial bores 85 which typically diffuse said protection gas in a radial direction directly to a nozzle 86 surrounding said diffuser element 84, said tip holder 87 and said contact tip 82.
The nozzle 86 is very warm during the use of the welding torch 80, typically approximately at 200°C or 300°C, and determines a significant heating of the protection gas which then subsequently flows towards the exit of the nozzle 86 to protect the welding bath.
A disadvantage of the existing welding torches resides in that they do not permit a good control of the temperature of the welding alloy.
This is principally due to the contact tip 82 which warms up excessively during the time reaching very high temperatures due to the transfer of said electric current to said welding wire.
In the case of a pulsed arc welding the fusion of said welding wire is determined by a series of pulses of electric current which are generated by an electric generator when through a pushbutton an advancement of the welding wire through said metallic wire guide 88 is actuated.
Usually said wire guide 88 has the function of guiding said welding wire up to the contact tip 82 and comprises a metallic spiral realized with a metal wire with round section which has an inner diameter slightly greater than the diameter of said welding wire.
Another disadvantage resides in that during the advancement of the welding wire in case of an excessive bending of said wire guide a greater friction between the welding wire and said wire guide is determined.
This increase of the friction determines consequently a lesser advancement of the welding wire and also determines an advancement speed which is not constant and which moreover is not synchronized with the actuation of the advancement of the welding wire.
This determines the disadvantage of the loss of synchronization between the electric pulses produced for melting said welding wire and the advancement of the welding wire.
Consequently this phase difference of the advancement of the welding wire and the loss of synchronization with the electric pulse generator affect the quality of the welding and complicate significantly the use of the welding torch.
Aim of the present invention is to realize an arc welding torch of the type MIG or MAG having a limited number of components and allowing a reduction of the maximum temperature of said contact tip, together with a reduced maintenance.
Other aim is to realize an arc welding torch of the type MIG or MAG allowing to improve the quality of the welds and permit a better control of the temperature of the welding alloy during a welding.
Another aim is to have an arc welding torch of the type MIG or MAG which permits to have a reduced friction and allows a suitable advancement of the welding wire even when the wire guide in which the same passes is curved.
A further aim is to have an arc welding torch of the type MIG or MAG which permits to reduce the protective gas consumption.
Another aim is to have a welding torch which is economically advantageous.
This aims according to the present invention are reached by realizing a welding torch as exposed in claim 1.
Further characteristics of the invention are highlighted by the subsequent claims.
The characteristics and the advantages of a welding torch according to the present invention will be more evident from the following description, exemplificative and non limitative, referred to the annexed schematic drawings in which:
The present invention refers to an arc welding torch 10 in particular of the type MIG or MAG, which comprises a metallic tubular lance body 50 capable to conduct an electric current and inside which a protection gas of a welding bath flows, and comprises a metallic contact tip 20 provided with an axial through bore 26 for the passage of a welding wire.
According to the present invention said contact tip 20 is directly partially insertable inside and constrainable to an extremity 51 of said metallic lance body 50 or said contact tip 20 is partially insertable inside and constrainable to a metallic connection sleeve 60 which can be fixed to said extremity 51 of said metallic lance body 50, said contact tip 20 respectively defining with said extremity 51 of said lance body 50 or with said connection sleeve 60 at least a longitudinal internal passage 70 capable to determine a longitudinal flow of the protection gas which in this way comes directly in contact with an external lateral portion 30 of said contact tip 20 in order to cool the same and to permit also the passage of said protection gas of said welding bath.
Preferably said contact tip 20 is directly and partially insertable in said extremity 51 of said metal lance body 50 and constrainable to the same, in order to define said at least one longitudinal internal passage 70.
Alternatively and preferably said arc welding torch 10 of the type MIG or MAG comprises said metallic connection sleeve 60 which can be fixed to said extremity 51 of said metallic lance body 50, and also said contact tip 20 is partially insertable internally and constrainable to said metallic connection sleeve 60, in order to define said at least one longitudinal internal passage 70.
Said metallic connection sleeve 60 is able to receive said current from said lance body 50 and transfer it to said contact tip 20, said metallic contact tip 20 being capable of transferring said electric current to said welding wire to determine the melting of the same in order to determine a welding bath.
Advantageously this permits to obtain a reduction of the number of components of said welding torch 10, because in this way a production of a contact tip holder and of a diffuser of said protection gas, typically not realized in a metallic material, is avoided.
In fact the contact tip 20 is able to couple itself directly to said lance body 50 or directly to said metallic connection sleeve 60, and in this way it is able:
This permits also a reduction of the production cost, because it permits to produce a smaller number of elements, and also a time and assembly costs reduction of the welding torch 10.
Referring to the figures, it can be noted that at least one internal longitudinal passage 70 is disposed inside with respect to said lance body 50 or said connection sleeve 60, and also it is evident that said metallic contact tip 20 defines said at least one internal longitudinal passage 70 with respect to said extremity 51 of said lance body 50 or internally to said connection sleeve 60.
In this way a direct flow of protection gas is formed in a longitudinal direction which gets directly near said outer side portion 30 of said contact tip 20 by cooling the same.
In other words said direct flow of protection gas, coming out from said extremity 51 of said lance body 50 is directly introduced in said at least one internal longitudinal passage 70, in order to come in contact directly with said external lateral portion 30 of said contact tip 20, by cooling the same.
On the contrary the protection gas with a diffuser of the known art provided with outlet radial bores, which are orthogonal with respect to a longitudinal direction 98, could not determine anyway a direct contact and a cooling of said contact tip, also because the gas in the known art is heated by the nozzle before reaching the contact tip.
In the welding torch 10 of type MIG or MAG according to the present invention the protection gas is also used as a cooling gas of the contact tip 20 and advantageously also of the connection sleeve 60 if present.
Said contact tip 20 is an element subjected to a high wear and therefore it must be frequently replaced.
Consequently said metallic connection sleeve 60 being constrained to said contact tip 20 is also subjected to wear and therefore it must also be replaced, even if less frequently.
According to a preferred embodiment it is possible to realize said contact tip 20 in a single piece with said sleeve 60, and in such a case to avoid wear problems said extremity 51 of the lance body 50 is realized in a copper alloy having a high hardness and a good electrical conductibility or it is provided with a wear resistant coating.
Preferably said at least one internal longitudinal passage 70 is at least a groove 32 realized in said external lateral portion 30 of said contact tip 20 or inside said metallic connection sleeve 60 or inside said extremity 51 of said lance body 50.
Preferably said at least one groove 32 is realized in said external side portion 30 of said contact tip 20 and it permits the passage of said protection gas from a first extremity 22 to a second extremity 24 of said contact tip 20, and is also very simple to realize.
Advantageously this permits to have a contact tip 20 capable of cooling itself exploiting a longitudinal flow of said protection gas, and also of having at the same time a further function of diffusing the protection gas around said welding bath.
In particular said at least one groove 32 is realized from a first base surface of said first extremity 22 and it extends continuously towards said second extremity 24 at least for a portion of said contact tip 20 which is insertable from said first extremity 22 in said metallic connection sleeve 60 or in said lance body 50.
Advantageously said at least one groove permits a good control of the melting temperature of said welding wire, because in this embodiment it permits to obtain a high heat exchange surface, which through the passage of said longitudinal flow of said protection gas advantageously determines a very good cooling of said contact tip.
By properly dimensioning the depth and the number of grooves 32 it is therefore possible to obtain a contact tip 20 permitting a very precise control of the maximum temperature of said contact tip 20 obtained by actuating a direct cooling of said contact tip by passing said protection gas through said at least one groove 32.
This permits to obtain a contact tip 20 having a high control of the maximum temperature of the same, determining advantageously a significant improvement of the welding quality.
This also permits to maintain a limited encumbrance of said contact tip 20 by reducing at the same time the maximum temperature of the same, by increasing the welding quality and of the useful life of said contact tip 20.
The decrease of the maximum temperature of said contact tip 20 permits also to increase the electric current and the speed of the welding wire by determining a greater welding speed, with a reduction of times and costs for the realization of big goods and also permits to reduce the energetic consumptions with the same electric current.
Furthermore the greater cooling capacity of said contact tip 20 determined by said at least one groove 32 permits a reduction of the dimensions of said contact tip 20 itself, consequently permitting also an advantageous reduction of the transversal section of said welding torch with a consequent reduction of the weight and of the encumbrance of the same.
In this way it is possible to realize a contact tip 20 and a welding torch provided with a smaller nozzle which permits to work more easily in particular also in narrower spaces.
Preferably said contact tip 20 has a diameter comprised between 6 and 16 mm and also comprises a threaded portion, preferably realized on said external lateral portion 30, which permits to partially insert and axially constrain said contact tip 20 internally inside said metallic connection sleeve 60 or internally inside said extremity 51 of said lance body 50, so permitting a good passage of electric current and at the same time allowing for a great longitudinal flow of said protection gas.
Advantageously this permits to easily realize a stable connection which permits a good passage of electric current necessary for melting such welding wire.
Preferably said metallic connection sleeve 60 is made preferably of copper and/or its alloys to reduce the resistivity to a minimum and to permit a better transmission of said electric current to said metallic contact tip 20, also made preferably of copper and/or its alloys.
Preferably said second extremity 24 is preferably tapered in order to better diffuse said protection gas.
Preferably said contact tip is made of copper or its alloys to reduce the resistivity to a minimum.
Preferably said at least one groove 32 extends from said first extremity 22 towards said second extremity 24, in particular up to said second extremity, following a substantially rectilinear or curvilinear path.
Advantageously this permits to easily realize said at least one groove 32.
Preferably said at least one groove 32 extends from said first extremity 22 towards said second extremity 24 following a substantially spiral or helical path.
Advantageously, the volume of said protection gas being the same, this increases the contact time with said contact tip 20, also increasing the cooling of the same.
According to a preferred embodiment said at least one groove 32 extends from said first extremity 22 to said second extremity 24 following a substantially spiral or helical path.
Preferably said at least one groove 32 are at least two grooves 32 substantially linear and/or curvilinear.
Preferably said at least one groove 32 are at least three grooves 32 substantially linear e/o curvilinear.
Preferably said at least one groove 32 are at least four grooves 32 and in particular at least eight grooves 32 substantially linear or curvilinear which extend from said first extremity 22 towards said second extremity 24 and which are in particular realized uniformly radially spaced in said external lateral portion 30.
Advantageously this permits an easy production of a contact tip 20 which permits a great flow of said protection gas and which at the same time also permits a great cooling of the same.
Said welding torch further comprises a metallic welding wire guide 40 capable to guide said welding wire in particular up to said bore 26 of said contact tip 20.
According to the present invention said wire guide 40 comprises a double flexible metallic spiral formed by a first flexible metallic spiral 42 and by a second flexible metallic spiral 44 which are wrapped together side by side in order to obtain said tubular wire guide 40, said first flexible metallic spiral 42 having a first smaller internal diameter 43 and said second flexible metallic spiral 44 having a second smaller internal diameter 45, said second smaller internal diameter 45 being greater than said first smaller internal diameter 43 and it also has with it a ratio the value of which is greater or equal to 1,05 and in particular is greater or equal to 1,1 in order not to touch said welding wire during its advancement in particular when said wire guide 40 is bent, so reducing consequently the friction.
Advantageously in this way said welding wire is able to be supported only by one metallic spiral, whereas the other has only a function of lateral containment, i.e. the function of avoiding that the wire comes out from said metallic wire guide 40.
In this way advantageously the friction between said welding wire and said wire guide 40 by length unit of said wire guide 40 is substantially reduced of at least 50%, as the number of contact points of said wire guide 40 with said welding wire is significantly reduced.
Advantageously this reduces significantly the friction and permits to maintain a substantially constant and synchronized speed with an actuation of the advancement of said welding wire especially in the case of a pulsed arc welding torch.
Preferably said welding torch of type MIG or MAG is provided with an electric pulse generator in particular with pulsed arc for melting said welding wire.
Preferably said first flexible metallic spiral 42 and said second flexible metallic spiral 44 have both a substantially circular or oval section.
Alternatively preferably said first flexible metallic spiral 42 has a section substantially circular whereas said second flexible metallic spiral 44 has a substantially oval or rectangular section, or vice versa.
Advantageously this permits to further reduce the weight as by means of said oval or rectangular section the quantity of material by length unity of said wire guide is lower, with the same outer diameter 47 of said wire guide 40 and the same lower internal diameters 43 and 45.
Preferably said wire guide 40 is realized in a metallic material particularly steel and/or its alloys in order to obtain a reduced production cost and a high wear resistance.
Advantageously according to a preferred embodiment said arc welding torch comprises preferably a nozzle 90 provided with at least an exit opening 95 of the protection gas, said at least one exit opening 95 being asymmetrical with respect to a longitudinal axis 98, in order to better diffuse the protection gas of the welding bath along a transversal direction.
Preferably said nozzle 90 is also preferably asymmetric with respect to said longitudinal axis 98, so accelerating said protection gas in said transversal direction, in order to permit an increase of the speed on said welding bath and a faster cooling of the same.
So it was seen that a welding torch according to the present invention realizes the previously evidenced aims.
Furthermore, in practice the used materials, and also their dimensions and components, could be of any kind according to the technical needs.
This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.